Catalyst for preparing aldehyde

ABSTRACT

A monolithic, structured catalyst for the preparation of aldehydes. Alcohol is converted to a corresponding aldehyde by partial oxidation of the alcohol using the catalyst which includes an active catalytic material and a monolithic, inert carrier for the same. The active material includes oxides of molybdenum and oxides of chromium, vanadium, aluminum, iron, tungsten, manganese and mixtures thereof.

This is a division of application Ser. No. 07/596,677, filed Oct. 12,1990, now U.S. Pat. No. 5,118,868.

The present invention relates to the preparation of aldehyde. Inparticular, the present invention is concerned with a monolithicstructured catalyst for use in the preparation of aldehydes.

A widely employed process for the production of formaldehyde onindustrial scale is oxidation of methanol to formaldehyde. This processis usually carried out by passing methanol-containing gas over oxidationcatalyst.

Due to the heat developed during the oxidation of methanol the processis ordinarily carried out in a wall cooled, tubular reactor.

An important feature of this process is the performance of the catalystand reactor, which is measured as the as the optimum yield offormaldehyde calculated on the mole ratio of formaldehyde obtained andmethanol fed to the reactor.

Catalysts providing a high selectivity during the oxidation of methanolto formaldehyde, are the known unsupported catalysts based on the oxidesof iron and molybdenum, such as Fe₂ (MoO₄)₃ --MoO₃ as disclosed in U.S.Pat. No. 1,913,405 and chromium oxide stabilized unsupported ferricoxide-molybdenum oxide catalysts as mentioned in U.S. Pat. No.3,194,771.

It is well known that the selectivity of the particle shaped oxidationcatalysts decreases with increasing conversion to aldehyde resulting ina barrier for the optimum yield obtainable. Thus, at conversion levelsof methanol at about 98-99% the selectivity decreases with increasingmethanol conversion giving a maximum obtainable formaldehyde yield ofbetween 92-93%. To improve the selectivity the catalyst is used as smallparticles, possibly supported on a carrier as suggested in U.S. Pat.Nos. 4,181,629; 4,471,141; and 1,028,353, which can be used in fluidizedbeds.

A serious drawback of the known particle shaped oxidation catalysts is,however, pressure drop limitations caused by use of small particles intraditional fixed bed reactors. Small supported catalyst particles have,so far, not been successfully used in fluidized bed reactors onindustrial scale apparently due to the lack of sufficient attritionresistance of the catalyst particles.

It has now been found that Mo based catalysts supported on a monolithiccarrier provide an oxidation catalyst with an improved performanceduring conversion of alcohols to corresponding aldehydes, by reducedpressure drop compared to a catalyst bed of particulate catalyst. It hasfurther been observed that when the monolithic supported catalyst isused in an adiabatic reactor after a wall cooled reactor, the formationof by-products such as formic acid and dimethylether is reduced.

Pursuant to these findings and observations, an object of the presentinvention is to provide an improved catalyst for the conversion ofalcohols to aldehydes, which catalyst comprises as active catalyticmaterial mixed oxides of molybdenum and a further component M, wherein Mis selected from the group of chromium, vanadium, aluminum, iron,tungsten, manganese and mixtures thereof in a molar ratio Mo: M ofbetween 1 and 5, the improvement of which comprises a monolithicstructured inert carrier for the catalytic active material.

In a preferred embodiment of the invention the monolithic structuredcarrier is reinforced by a binder applied thereon.

The amount of the active material on the monolithic carrier may varyfrom 1 to 90% by weight with respect to the total amount of activematerial, carrier and binder. Preferably, the active material is loadedon the carrier in an amount of 80-90% by weight calculated on the totalamount of active material, carrier and binder.

A further object of the invention is the use of the improved catalystfor the oxidation of alcohols to corresponding aldehydes, preferablymethanol to formaldehyde.

The improved catalyst of the present invention may be prepared by aprocess, comprising the steps of corrugating sheets of fibrous inertcarrier material;

coating corrugated sheets with a slurry, containing active catalyticmaterial and optionally a binder; and drying; and

calcining the corrugated and coated sheets.

Suitable fibrous carrier material for use in the invention is anyheat-resistant material, which is inert with respect to the conversionof alcohols to aldehydes, such as fibrous sheets of silica, with anaverage fibre diameter of between 50 and 250 micrometer and an averagefibre length of between 2 and 30 mm.

The fibrous sheets are corrugated in a conventional corrugating machineand formed into a monolithic structured body by rolling up a singlecorrugated sheet to a cylindrical body having straight channels throughthe body. Preferably the monolithic structured body is formed into across-corrugated structure by piling up a number of the corrugatedsheets to parallel layers with different orientation of the corrugationamong the layers.

In either case the monolithic body is loaded by immersion or washcoatingwith an aqueous slurry containing the catalytic active material andoptionally the binder for stabilizing the structure.

The catalytic active material for use in the invention may be obtainedby coprecipitation from an aqueous solution containing soluble compoundsof molybdenum and the component M in a molar ratio of Mo:M between 1 and5, preferably 1.5 and 3. The precipitate is dried and calcined toconvert the constituents to their active oxidic form. Alternatively, theoxides of molybdenum and of the component M, may be grounded togetherand calcined. In any case, the catalytic active material thus obtainedhas a specific surface area of 1 to 7 m² /g.

Suitable binders for reinforcing the monolithic structured carrier areany of the known binder materials, which are inert with respect to theoxidation of the alcohol, such as silica, titania and the like.

The thus prepared monolithic structured catalyst may be used inadiabatic and cooled reactors for the partial oxidation of an alcoholcontaining feed gas to a corresponding aldehyde.

The partial oxidation of e.g. methanol to formaldehyde may further beobtained in a number of adiabatic catalyst beds containing themonolithic catalyst according to the invention and connected in serieswith cooling and methanol injection between the beds.

Having thus described the general aspects of the invention the followingExamples are given to illustrate more detailed preferred embodimentsthereof.

EXAMPLE 1

160 ml of an aqueous solution containing 130 g Fe(NO₃)₃ ·9H₂ O and 43 gCr(NO₃)₃ ·9H₂ O and 140 ml of an aqueous solution containing 96 ml 25 wt% NH₄ OH and 131 g MoO₃ are mixed in an agitated vessel. The combinedsolution is evaporated to dryness and subsequently thermally decomposedat 250°-300° C. to remove NH₄ NO₃. The remaining solid is calcined at525° C. for 1 hour and finally grounded in a ball mill.

EXAMPLE 2

1377 ml of an aqueous solution of 772 g Al(NO₃)₃ ·9H₂ O and 768 gCr(NO₃)₃ ·9H₂ O are mixed with 2150 ml of an aqueous solution containing869 ml 25% NH₃ NH₃ and 873 g MoO₃.

The combined solution is then filtered and the obtained solid washedwith destilled water to remove NH₄ NO₃.

EXAMPLE 3

This Example illustrates the preparation of a monolithic structurediron-chromium-molybdate catalyst with straight channels through themonolith according to an embodiment of the invention, for use in thepartial oxidation of methanol to formaldehyde.

A sheet of silica rich heat-resistant paper of 0.25 mm in thickness andconsisting of silica fibres with a diameter of about 250 micrometer anda length of about 2 mm is corrugated by a conventionalcorrugating-machine, giving a corrugated sheet with a corrugation heightof about 2.5 mm. The corrugated sheet is then rolled up to a straightchannel monolith with an outer diameter of 50 mm and a height of 50 mm.

A slurry for immersing therein the so formed monolith is prepared bymixing 1200 g of the catalytic active material as prepared in Example 1and 845 g ammonia stabilized SiO₂ -binder, supplied by Monsanto Co.,Ruabon, United Kingdom under the tradename Syton T40, and 250 gdemineralized water.

The slurry is ball milled at ambient temperature for 24 hours, afterwhich the monolith is immersed repeatedly in the slurry and dried atambient temperature, until a final load of catalytic active material andbinder of 90% by weight calculated on the total amount of activematerial, binder and monolith. The monolithic catalyst is then dried at20° C. for 24 hours and calcined at 450° C. for 2 hours.

EXAMPLE 4

Preparation of a straight channel monolithic aluminum-molybdate catalystaccording to the invention.

A slurry for immersing therein the so formed monolith is prepared bymixing 360 g of the catalytic active material as prepared in Example 2and 90 g ammonia stabilized SiO₂ -binder, supplied by Monsanto Co.,Raubon, United Kingdom under the tradename Syton T40, and 818 gdemineralized water.

The slurry is ball milled at ambient temperature for 24 hours, afterwhich the monolith is immersed in the slurry, then dried at ambienttemperature and calcined at 420° C. for 30 min. This procedure wasrepeated twice giving a final load of catalytic active material andbinder of 77% by weight calculated on the total amount of activematerial, binder and monolith. The monolithic catalyst was finallycalcined at 600° C. for 90 min.

EXAMPLE 5

This Example illustrates the preparation of a cross corrugatedmonolithic iron-chromium-molybdate catalyst according to the inventionfor use in the oxidation of methanol to formaldehyde.

A number of corrugated sheets, as described in Example 3, each providedwith a liner made from the same material as the corrugated sheets, arepiled up as parallel layers, wherein the corrugation among the layers isat a right angle, giving a cross corrugated monolith.

The so formed monolith is washcoated once by the slurry prepared inExample 3 containing the active material and the binder, then dried at20° C. for 24 hours and calcinated at 450° C. for 2 hours.

Cylindrical bodies with a diameter of 21 mm and a height of 50 mm arecut out of the washcoated monolith.

The cylindrical bodies are washcoated again by the same slurry asmentioned above to an extent giving a final loading of active materialthereon corresponding t 80% by weight calculated on the total amount ofactive material, binder and monolith.

The monolithic supported catalyst is finally dried and calcinated asdescribed above.

EXAMPLE 6

This Example is carried out by a test of the cross corrugated monolithiccatalyst as prepared in Example 5.

The cross corrugated monolithic catalyst in the form of a cylindricalbody is fitted in a reactor tube with 21 mm i.d. and a height of 1200mm. The loaded height of the monolith is 900 mm.

The wall of the reactor tube is kept at 271° C. by a cooling bath. Feedgas consisting of 6.5 vol % CH₃ OH, 19.6 vol % O₂ and 74.2 vol % N₂ ispassed through the reactor tube at a space velocity of 6000 h⁻¹.

By passage through the monolithic catalyst 99.3% of the methanol in thefeed gas is converted to formaldehyde with a selectivity of 96.2%. Theyield of formaldehyde is thus 95.6%.

EXAMPLE 7

Comparative performance of pellets and monolithic catalyst.

3 pieces of the monolithic catalyst of Example 5 having a diameter of 50mm o.d. and a height of 50 mm with a total of 77 g active material areloaded in an adiabatic reactor having a diameter of 50 mm i.d.

The adiabatic reactor is connected to the outlet of the wall cooledreactor as described in Example 6 with the exception that the wallcooled reactor is loaded with 177 g crushed pellets of a conventionalformaldehyde catalyst, supplied by Haldor Topsce, Lyngby, Denmark,consisting of chromium promoted iron molybdate and molybdenum trioxide.

Feed gas, consisting of 8 vol % methanol, 9 vol % O₂ and nitrogen asbalance, is passed through the wall cooled reactor at a velocity of 1900Nl/h and a temperature of 271° C., whereby 95.5% of the methanol isconverted. The reacted gas leaving the cooled reactor is further passedthrough the monolithic catalyst fitted in the adiabatic reactor.

The inlet temperature of the gas to the adiabatic reactor is varied togive exit temperatures at the outlet of this reactor of 300° C., 350° C.and 400° C. The results obtained by this experiment are shown below inTable 1. The pressure drop over the monolithic catalyst is 32 mm Hg.

In a further experiment the performance of the monolithic catalyst iscompared to-the conventional formaldehyde catalyst as described above.The monolithic catalyst loaded in the adiabatic reactor is now replacedby 77 of the conventional catalyst, crushed to 1.0 to 1.7 mm particles.

At the same feed gas composition and under comparable conditions as inthe first experiment a comparable thaol conversion rate and selectivityis obtained, except that the pressure drop over the conventionalparticulate catalyst has risen by about 20% compared to the monolithiccatalyst to 40 mm Hg. The results of this experiment are listed below inTable 2.

                                      TABLE 1                                     __________________________________________________________________________    Performance of monolithic formaldehyde                                        catalyst in adiabatic postconverter                                                           Yield              ΔT                                             Conversion                                                                          HCHO                                                                              CO DME CO.sub.2                                                                         HCOOH                                                                              exp.                                                                             Δp.sup.§)                              %     C % C %                                                                              C % C %                                                                              ppm*)                                                                              °C.                                                                       mmHg                                    __________________________________________________________________________    Exit cooled reactor                                                                     95.6  91.8                                                                              1.8                                                                              1.9 0.1                                                                              226  -- --                                      Exit adiabatic                                                                reactor (°C.)                                                          300° C.                                                                          99.1  94.2                                                                              2.5                                                                              1.8 0.6                                                                              150  23.                                                                              32.                                     350° C.                                                                          99.6  93.8                                                                              3.7                                                                              1.5 0.6                                                                              105  34.                                                                              32.                                     400° C.                                                                          99.5  91.9                                                                              5.3                                                                              1.5 0.9                                                                               95  52.                                                                              34.                                     __________________________________________________________________________     *)Given as ppm (wt %) HCOOH in 37% wt % aqueous HCHO solution.                .sup.§) Including a pressure drop of about 25 mm Hg over the empty       reactor system.                                                          

                                      TABLE 2                                     __________________________________________________________________________    Performance of crushed (1-1.7 mm) conventional formaldehyde                   catalyst in adiabatic postconverter                                                           Yield              ΔT                                             Conversion                                                                          HCHO                                                                              CO DME CO.sub.2                                                                         HCOOH                                                                              exp.                                                                             Δp.sup.§)                              %     C % C %                                                                              C % C %                                                                              ppm*)                                                                              °C.                                                                       mmHg                                    __________________________________________________________________________    Exit cooled reactor                                                                     95.6  91.9                                                                              2.2                                                                              1.4 0.1                                                                              220  -- --                                      Exit adiabatic                                                                reactor (°C.)                                                          300° C.                                                                          99.3  94.4                                                                              2.7                                                                              1.6 0.5                                                                              152  18.                                                                              40.                                     350° C.                                                                          99.8  93.8                                                                              3.9                                                                              1.5 0.7                                                                              103  24.                                                                              40.                                     400° C.                                                                          99.9  93.0                                                                              4.3                                                                              1.3 1.3                                                                               94  35.                                                                              45.                                     __________________________________________________________________________     *)Given as ppm (wt %) HCOOH in 37% wt % aqueous HCHO solution.                .sup.§) Including a pressure drop of about 25 mm Hg over the empty       reactor system.                                                          

EXAMPLE 8

The straight channel monolithic catalyst of Example 4 is tested duringthe preparation of formaldehyde by partial oxidation of methanol in asimilar procedure to that of Example 7. 3 pieces of the monolithiccatalyst of Example 4 having a diameter of 50 mm o.d. and a height of 50mm with a total of 72 g active catalytical material are now loaded inthe adiabatic reactor having a diameter of 50 mm i.d.

At a space velocity of 6700 h⁻¹ and an exit temperature of 350° C. inthe adiabatic reactor the conversion of methanol to formaldehydeincreases from about 95% at the exit of the wall cooled temperature to99.3% in the exit gas of the adiabatic reactor, giving a yield offormaldehyde of 92.5%. The pressure drop over the monolithic catalyst ismeasured to 33 mm Hg including a pressure drop of about 25 mm Hg overthe empty reactor system.

EXAMPLE 9

In this Example a straight channel monolithic catalyst, as described inExample 3, is tested in a simulated process for the partial oxidation ofmethanol to formaldehyde. The partial oxidation of methanol is computedto be carried out in 4 adiabatic catalyst beds connected in series withcooling and methanol injection between the beds. 12,500 Nm³ /h feed gascontaining 9.1 vol % methanol, 10 vol % O₂ with nitrogen as balance andmixed with 336 Nm³ /h of methanol containing gas are passed at a totalvolumetric flow rate of 12,836 Nm³ /h to the first catalyst bed. To theeffluent of each bed 1-2 further 336 Nm³ /h of the methanol containinggas are added before passing to the next bed. To the effluent of bed 3247 Nm³ /h of the methanol containing gas are added before it is passedto bed 4.

The temperature at the inlet of each catalyst bed is adjusted to about250° C. by heat exchange. The content of the active catalytic materialis tabulated in Table 3 below together with the above mentioned processparameters. The overall conversion of methanol at the outlet of catalystbed 4 is calculated to 98.4%.

                  TABLE 3                                                         ______________________________________                                               Total flow vol %      Temp.  Catalytic                                 Catalyst                                                                             (Nm.sup.3 /h)                                                                            Methanol   (C.°)                                                                         active                                    bed    inlet      in added gas                                                                             inlet  material (kg)                             ______________________________________                                        1      12,836     2.6        250    410                                       2      13,338     2.5        249    480                                       3      13,837     2.6        251    480                                       4      14,229     2.2        248    780                                       ______________________________________                                    

At a linear velocity of 0.27 Nm/s a pressure drop of 47 mm Hg over themonolithic catalyst is calculated, when using 8.5 m³ of the catalystwith a bulk density of 0.27 g/cm³.

To reach 98.4% methanol conversion, as it is the case in the abovecomputation model, a total of 2.2 m³ of the crushed conventionalformaldehyde catalyst with a particle diameter of 1.5 mm and a bulkdensity of 1 g/cm³ would be needed, giving a pressure drop over thecatalyst of 375 mm Hg at an equivalent linear velocity as mentionedabove.

Having thus described the invention in detail with respect to preferredembodiments thereof, it is to be understood that various changes, whichwill be readily apparent to those skilled in the art are contemplated aswithin the scope of the present invention, which is limited only by theclaims which follow.

We claim:
 1. A catalyst for converting an alcohol to a correspondingaldehyde by partial oxidation of the alcohol, the catalyst consistingessentially of: an active catalytic material consisting essentially ofmixed oxides of molybdenum and a further component M, wherein M isselected from the oxides of chromium, vanadium, aluminum, iron,tungsten, manganese and mixtures thereof, in a molar ration Mo: M ofbetween 1 and 5; and a monolithic structured inert carrier for thecatalytic active material.
 2. The catalyst of claim 1, wherein themonolithic structured carrier has straight channels through thestructure.
 3. The catalyst of claim 1, wherein the monolithic structuredcarrier has a cross corrugated structure.
 4. The catalyst of claim 2,wherein the monolithic structured carrier comprises silica-rich fibershaving an average diameter of between 50 and 250 microns and an averagelength of between 2 and 30 mm.
 5. The catalyst of claim 4, wherein themonolithic structured carrier is reinforced by a binder.
 6. The catalystof claim 1, wherein the catalytic active material is from 1 to 90% ofthe catalyst, calculated on the total amount of active material andmonolithic carrier.
 7. The catalyst of claim 6, wherein the catalyticactive material is from 80 to 90% by weight of the catalyst, calculatedon the total amount of active material and monolithic carrier.
 8. Acatalyst for converting an alcohol to a corresponding aldehyde bypartial oxidation of the alcohol, the catalyst comprising: an activecatalytic material comprising mixed oxides of molybdenum and a furthercomponent M, wherein M is selected from the oxides of chromium,vanadium, aluminum, iron, tungsten, manganese and mixtures thereof, in amolar ratio Mo: M of between 1 and 5; and a monolithic structured inertcarrier for the catalytic active material comprising silica-rich fibershaving an average diameter of between 50 and 250 microns and an averagelength of between 2 and 30 mm.
 9. The catalyst of claim 7, wherein themonolithic structured carrier is reinforced by a binder.